Water-stop expansion joint



WATER-STOP zxrmsxou JOINT Filed April 24, 1945 wangmoonn 2 man nousUNFILLED BITUMINOUS mean. PORILS MATERIEL UNFn-LED UNFILLED UATERPROOFEDA WATERPROOFED 1 mnsnc, com-now I V ASPHALI'IC 2 g RUMER B mAs'rlc a ERESIN mm A5 A5 Russzmzeo IN VEN TOR.

ALBERT FSCHERQ BY ATTORNEY Patented Nov. 25, 1947 UNITED STATES PATENTOFFICE WATER-STOP EXPANSION JOINT Albert C. Fischer, Chicago, Ill.

Application April 24, 1945, Serial No. 590,009

12 Claims.

1 This invention relates to expansion joints for use in weather-proofingthe spaces left between constituent members of masonry structures for.the expansion of such members under changing sional integrity, with itsmargins hermetically,

anchored in the masonry members so that it will be held across the jointand particularly across any spaces that open between said masonrymembers and the core of the joint, during temperature contraction of themembers; and with the anchoring connections between the apron andmasonry members fashioned to permit of lost motion without losing thehermetic nature of the anchorage in case of excessive tension on theapron; and with the apron constituted by either an independent mass ofnon-flowing resilient material extending from one masonry member throughthe core to the other masonry member, or by anchoring wings carried byand hermetically united to or integral with and having their continuity(in producing the water-stop) established by a horizontally alinedintermediate portion of the core.

One important identifying characteristic of the present inventionresides in the fact that instead of using sheet metal andincurring thedisadvantages inherent therein for the production of a water-stop, as anadjunct of a plastic expansion joint, the invention avails of theimportant advantages accruing from the use of a mass of elastic orresiliently deformable material, or some tensionally strong compound ofbituminous or asphaltic material with the advantages, among others, thatthe seepage moisture controlling unit is free from the impairinginfluence of corrosion; its effective field of functioning is localizedwithin vertically narrower limits; it remains in more efl'ectiveresistance to surface water and water from the base of the joint; it iswell adapted for multiplication of units at any desired verticallyspaced levels of the joint; and it is better protected againstimpairment by shearing action resulting from relative movement betweenthe masonry members in a direction perpendicular to the plane of themembers.

The expansion joints in accordance with the present invention alsoutilize as parts thereof,

I either in the core portions or the water-stop portions, a rubberizedbituminous material characterized by a high degree of disten'dability,compressibility, recuperative power, adhesiveness and ability tomaintain bond at subfreezing temperatures as low as 15 F. on account ofits tacky texture. This material is a rubberized bituminous compositionwhich may be compounded of different ingredients and in diflerentquantities, in

dependence upon the specific applications in which the same may be used.

By way of illustration, and not by wayof limitation, the new rubberizedbituminous material having the properties above identified may becomposed of the following ingredients:-

Per cent Reclaimed rubber 17.5 (12 to 20.0) Hydro-carbon oil 3.8 (1 to10.0) Polymerized coumarone Synthetic rubber (Buna S) 4.7 (2 to 10.0)Oil (S. V. superior base) 20.0 (13 to 23.0) Resin 7.5 (2 to 12.0)Asphalt (having a melting point between from about 90 to 180 F.) 45.0(40 to 50.0)

The S. V. superior base oil in the above formula has the followingcharacteristics:

Baum gravity 12.9 Flash point TL. 500 Pour poin F 25 Fire tes F 590Viscosity, Saybolt Universal at Fahrenheit,

280 seconds Color Dark red commodation in spaces provided by the cement7 matrices surrounding temporarily compressed wings or absorbed by thefibrous layers of the core temporarily compressed by pressure of .thedisplaced cold fiow mastic layer .or layers or by the masonry actingupon the several layers. As conducive to these functions the fibrous,sponge-rubher or other compressible layers, while preferablywater-proofed with rubberized mastic, such weterproofing is limited tosurface coating held to the core by shallow infiltration and their poresor spaces are so protected from obliteration whether said pores are thenormal pores of a sponge structure or are in individual fibers orbetween such fibers, that the wings or layers characterized by theirpresence will yield to pressure without causing extrusion of cold fiowconstituents of the joint.

Another identifying characteristic of some forms of the inventionresides in the cooperation of the tensionally strong waterstop union ofthe wings with the core and the hermetic anchorage of the wings of theapron in the masonry whereby tension through the apron upon the core andespecially resilient layers of the core, expands the core duringretraction of the masonry and influences return of cold flow material,in a measurable degree, to its original status in the joint.

Other identifying characteristics and especial- 1y those arising fromthe employment of certain materials for the production of thenonextruding water-stop expansion joint will appear as the descriptionproceeds in detail.

In the accompanying drawing are shown in sectional perspective, sixdifferent constructions of water-stop expansion joints comprisingexpansion cores carrying elastic apron-forming anchoring wings inaccordancewith the present invention,- which are adapted to be embeddedin masonry sections as shown generally in Fig. 1, to-wit:

Fig. 1 shows an embodiment in which the core is three-fold and consistsof two outer layers of plastic material and an intermediate compressiblelayer of fibrous material;

Fig. 2 shows an embodiment employing a single layer compressible coremade of fibrous material;

Fig. 3 shows an embodiment employing a three layer core consisting of amiddle layer of cold flow plastic material housed between twocompressible outer layers of fibrous material that carry apron-formingwings made of dovetailed shells of metal having an elastic filler ofplastic rubberized bituminous material;

Fig. 4 shows an embodiment employing an inherently resilient singlelayer core, homogeneous as to constituency (for instance, cork, corkrubber, resin cork, or the like) and having the elastic (sponge rubber,for instance) wings mortised into tension transmitting'relation to thecore;

Fig. 5 shows an embodiment in which an asphaltic middle layer is housedbetween two protective rubberized bituminous outer layers to which areattached water-stops of sponge rubber or rubberized bituminous material;and

Fig. 6 shows an embodiment of the invention geneity and integrality ofmaterial for substantially the whole joint, for instance, sponge rubber,rubberized bitumen or other Water-insoluble deformable materials thatare non-flowing or do not take on a permanent set when displaced bycompression or distension.

Referring to the drawings more in detail, A, in Fig. 1, represents themiddle layer of a threefold core of an expansion joint; which said layeris understood to be made of matted, felted or otherwise assembled fibersor subdivisions of organic, metallic or animal substance, having formretaining mass integrity with or without internal binding substance andwith a jacket of any suitable waterproofing material and preferably withits internal pores or spaces unfilled or vacant to a degree that leavesthe mas highly compressible.

B, B represents layers of bituminous material united to said middlelayer with a degree of integrity that admits of the transmission of sub-5 stantial stresses of tension from one side of the resultant core tothe other; and C represents anchoring wings of resiliently deformablematerial, ior example, sponge rubber, mounted upon opposite faces ofsaid core, preferably by adhesion through means of vulcanization,cementing or otherwise to the outer layers B of said core; theseanchoring wings being so located upon the core A, B that when said coreis introduced as a dividing confine in a mold used in the roduction ofcement pavements (for instance) and cement is poured against theopposite faces of said core not only will the said core define theexpansion space .between the masonry members, but the wings C willbecome embedded and hermetically anchored in the said masonry members;and two of the wings that are in horizontal alinement together with aportion of the core lying between them, will constitute a watersheddingapron or Waterstop extending from one of the poured masonry members,across the vertical plane in which said member meets the contiguous faceof the core; across the horizontal area of the core; and across theplane of meeting between the opposite face of said core and the other ofsaid masonry members. In short, the said masonry members which arepoured against the opposite faces of the expansion joint core will holda resiliently deformable apron in position across any crack or .spacethat could possibly open up between the joint and either masonry member.The anchoring wings C may be formed of rubberized bituminous materialprepared in accordance with the disclosures in the above-mentionedapplications, which become engaged adhesively to the layers B of thecore and become adhesively embedded in the matrices of the masonrysections.

The shape of the wings (dovetail or other tapering form), and that ofthe matrices formed about them is such that the hermetic character ofthe anchorage continues throughout the functioning of the joint, as willhereinafter appear.

The integrality of the anchoring wings and the core or integrity of theunion between-them will be such as to enable the apron to resist a sub-50 stantial degree of tension developed in the apron by contraction ofthe masonry members. This tensional resistance, however, will be ayielding resistance afforded by inherent resiliency or at leastelongation of the apron structure as a whole;

55 moreover, provision is made for lost motion between the anchoringwings and the masonry members through means of the tapering section ofwings and the corresponding convergent z of the walls of the matricescast about the wings, which enables each wing by accepting transversecompression, to slide toward the mouth of its confining matrix as themasonry member draws away. The angle of the faces of the wing and matrixto the axis of contraction movement being well beyond the slippingangle, the initial relation of these parts is automatically resumedunder return movement of the masonry member due to thermal expansion. Animportant functional characteristlc of an anchorage involving thetapered form of wing and matrix is that the hermetic seal of the jointis maintained notwithstanding the described relative movements betweenthe parts.

According to Fig. 2, the core member of the joint consists of a body Aof fibers, felted, matted or otherwise collected in a form having massintegrity and bound by some degree of adhesive binder but withoutsaturation or other pore filling characteristic; and preferably .havinga water proofing coat of bituminous, asphaltic or like material mountedthereon through means of shallow infiltration into surface pores of themass and therefore capable of partaking of deformation int-- relation,to the joint as described in connection they are mortised into the coreby undercut grooves and dovetailed tongues and cemented in place. Thecoating on thiswcompressible core, especially at the upper end will besuch as to enable the end to assume a position in the surface of thepavement. Or said end may, in accordance with the known expedient,terminate a sufiicient distance short of the surface of the pavement, toadmit a filler strip of core-material to take up the erosion of trafiic.With a core of this kind, resumption of initial condition, or spacefilling dimension will be greatly assisted by tension imparted throughthe wings, from the contracting masonry sections.

In Fig. 3 the core is three ply as in Fig.1, but the layers ofcore-forming materials are, a middle layer B of bituminous materialhoused between and cemented to two waterproofed fiber layers A A; andthe anchoring wings C are in the nature of shells of metal, hard rubber,vulcanite or what not, having permanently retained fillings C of plasticrubberized bitumen Or other sluggishly deformable adhesive material. Inthis case the filling 0 X forms a part of the apron since it adheres, tothe sides of the waterproofed fibrous layers A under pressure of theconcrete, and when the concrete retracts the shells C will withdraw withit, but the filling will be drawn out without leaving its adhesion tothe fiber and there will not be left any crack through which moisturemay pass. In this case, instead of the sponge rubber wing stretching asa whole in maintaining the moisture dam, the filling alone draws out.When conditions are reversed and the concrete expands and thrusts theshell toward the core, the

filling will flow largely back into the shell, but" partly into anyspace temporarily existing between the core and the masonry.

Thus the joint, made to include reservoirs of crack-healing material anda shell such as indicated at C borne by the masonry and containing asealing or healing mastic capable of flowing and with an adhesiveaffinity for the surface of the core at the mouth of the shell will,under the alternations of compression and retraction of the masonry,gradually ooze from the reservoir and maintain a seal at any space thatmay develop between the masonry and the core; and this function can bemade to obtain even though the coldflow mastic presented by the layer Bshould become dissipated, or is omitted from the organization of thejoint altogether.

In Fig. 4, the cold-flow mastic is omitted and the core comprises asingle body A of cork ground to small pieces and bound together forinstance, as

' in cork rubber or resin cork, while anchoring wings C are united tosaid core by mortised joints; the union between the core and the wingsbeing such that the wings, under retraction of the masonry members withwhich the joint is used, will with Fig. 1. The anchoring wings C 'may beformed of sponge rubber or rubberized bituminous material of the typedisclosed'in the above applications.

Fig. 5 employs for the core a slab-like body of asphaltic mastic B ofrather greater thickness than the asphaltic portion of previouslydescribed embodiments, and this body isfaced on either side withrelatively thinner layers A made of rubberized bituminous material thatcarry the anchoring and water-stop formin wings C. When these wings areformed of sponge rubber, they may be used to space the adhesive layers Awhen these are superposed in stacks prior to utilization. These wings ofsponge rubber may also be covered with rubberized bituminous coatings Dthat become embedded with said wings Hence, while there will be someextrusion of the asphalt mastic B at the road surface, due to pressureof the masonry under thermal expansion and while'the volume of themastic extruded will be suflicient to "mushroom" over the initiallyexposed edges of the core layers, this volume will be less and wastewill be less where compression is absorbed in a substantial degree byresiliently compressible spongy wings or like materials. Someembodiments of the present invention may therefore be regarded as lowextrusion waterstop expansion joints and other embodiments constitutenon-extruding water-stop expansion joints.

The non-bituminous layers entering into the core construction as hereindescribed may be any of numerous fabricated products available on themarket, such as wall board, insulating sheets and the like, or fibrousor subdivided organic orinorganic materials suitably felted, matted orotherwise aggregated into slab-like bodies of mass integrity. Theinvention contemplates mats or layers of puffed or bloated fibers, orfibers otherwise enlarged to render the mass more highly compressible,or absorbtive or otherwise more appropriate to the functions to beperformed.

From the foregoing it will be seen that the present inventioncontemplates the use of wings of rubber or rubberized bituminousmaterial as both molds for matrices and water-stops or seals forpreventing seepage of moisture into spaces that develop between thecores and the masonry. Moreover, these wings being in tensiontransmitting .union with faces of the cores as well as in tensiontransmitting anchorage upon the masonry members, may, under theirinherent elasticity, move with the section of masonry away from the corewhile still leaving their endsthat are united with the core, inwater-shedding relation to the core, thus stretching the apron-likewatershed so long as the masonry is in contraction. This stretching ofthe wings leaves spaces for the reception of displaced cold-flow masticthus reducing the quantity of mastic that extrudes from the joint.

Where, as illustrated in Figs. 2, 3, 4 and 6, cores made partly orwholly of fiber board, have in hermetic union with them, wings made ofsponge rubber or rubberized bituminous material and having dovetailedform, matrices form around these wings when the masonry sections arepoured; and when the masonry contracts tension imposed upon the wing atthe matrix opposed by the core at the point of union therewith,stretches the wings lengthwise sufficiently to leave recesses around thewings, in the matrices. But the union of a wing at the core and theembrace of the wing in the matrix both remain hermetic so thatseparation of the masonry from the core as much as an eighth of an inchwould not impair the eifect of the water-stop, nor would the apron beprevented from recovering its normal position as soon as the masonryagain expanded.

Where the wings are made of shells having fillings of rubberizedasphalt, compression under expansion of masonry and consequent flow ofthe mastic constituent of the core displaces the rubberized asphaltfiller and makes room for itself in the joint; and this would beeffective also if the shells of the wings were thin metal as well assolid rubber; and the same is true with any shell embedded in theconcrete and having fillings of rubberized asphalt.

An important advantage of using shells containing fiowable elastic,adhesive and stretchable material such as rubberized asphalt, asdistinguished from solid wings of rubber, arises from the effect offlowing the rubberized filler out against and causing it to adhere tothe confines oi the space that develops from the separation of themasonry and the fiber core and thereby inlayers of the compound,(without destroying their porosity), with rubberized bituminouscomposition of high degree of rubber qualities, and having high adhesiveaffinity for the walls of concrete. The layers so treated would beplaced intermediate ofpairs of water-stop seal-forming wings fabricatedout of sponge rubber or other suitable elastic material and would takecare of most of the bituminous material in case of escape either bypressing against the sponge rubber or oozing out of the top of thecrevice, but upon contraction there would be an elongation of thewater-stop strips which would keep any crevice which might developclosed and prevent infiltration of moisture. The rubberized bituminousmaterial on the sides of the joint would facilitate such action.

I have also shown that a complete joint may be fabricated from spongerubber or like elastic materials; for instance, rubberized bituminousmaterial, and with water-stops forming integral parts of the main body.This type of construction would be more expensive because of the priceof the ingredients necessary to fabricate it, but the wingextensions onthe side fabricated in key formation would act as waterstops on eitherside; upon contraction the wings will elongate and keep the crevicewaterproof; and they would work back to normal position upon expansion.

troducing a still more effective apron. Such an expedient has the'efiectof establishing a reservoir of apron-forming waterproofing material oneither side of the core; and any tendency of the surfaces to pull apartis compensated for by the blanket-like apron that immediately forms andwaterseals the gap.

A formula for a filler suitable for use in automatically settin up awater-stop under circumstances such as just described, is bitumlnousmaterial having rubber compounded therewith by solvent action; thebituminous material being materially in excess of the rubber. Specificformulas for the rubberized bituminous composition are set forthabove'in the introduction to the specification.

But I may use a cork and rubber joint material, or cork-joint material,or a resin-cork material and place on either side thereof, water-stopstrips made preferably out of sponge rubber but which could also beformed from a rubberized bituminous material. Any synthetic rubbermaterials such as neoprene or other recently devised compounds could beused, the elasticity of which, when the joint space is contracted, wouldenable them to stretch across the space left between the core or jointproper and the masonry walls; the

body of the material bein imbedded tightly in recesses in the walls andthe free portions thereof being adhered to the core and thus keeping thejoint closed against passage of any water beyond the resultantwater-stop.

Or, I may use as an asphaltic mass or mixture of a bituminous nature andsubject to cold-flow, any of the products now on the market; and I maycoat this mass of bituminous material and stiffen the same. with fibrousmatter of various sizes of subdivision and in various proportions; andin order to increase its elasticity coat the This case is acontinuation-in-part of my application Serial No. 381,745, filed March4, 1941 and issued April 24, 1945, as Patent No. 2,374,187.

I claim:

1. In combination, sections of masonry having between them a space intowhich they expand and a water-stop expansion joint comprising a. corefilling said space and having a face of rubberized bituminous materialcharacterized by a high degree of distensibility and adhesive power,said rubberized bituminous material comprising Per cent Rubber-likehydrocarbons 14 to 30 Asphaltic hydrocarbons 40 to 50 Hydrocarbon oil 14to 33 Resinous compounds 3 to 18 and a wing in hermetic tensiontransmitting union with said one face of said core and extendingtherefrom into and having hermetic tension transmitting anchorage in oneof said sections of masonry: said core and the wing united theretoconstituting a water-stop apron preventing seepage of water into saidspace.

2. The combination set forth in claim 1 wherein said wing is formed ofsponge rubber,

3. The combination set forth in claim 1 Wherein said wing is formed ofrubberized bituminous material similar to said face.

4. The combination set forth in claim 1 wherein the core includes in itsconstruction cold flow- .ing mastic material; and the wing is made ofcompressible material and is exposed to pressure of said mastic materialwhen the latter is under pressure of the expanding sections of masonry.

5. The combination set forth in claim 1 wherein the wing in effectingits hermetic anchorage to the section of masonry is confined in a matrixof the masonry, said matrix has a mouth toward which its sides convergeand through which the wing extends in establishing its union with thecore, and the said wing, by its compression between said convergingsides and without losing the hermetic nature of its anchorage, ispermitted to slide in said matrix and afiord lost motion to relieveexcessive tension upon the wing.

6. In combination, sections of masonry having between them a space intowhich they expand and a water-stop expansion joint comprising a corefilling said space formed of rubberized bituminous materialcharacterized by a high degree of distensibility-and adhesive power,said rubberized bituminous material comprising Per cent Rubber-likehydrocarbons 14 to 30 Asphaltic hydrocarbons 40 to 50 Hydrocarbon oil 14to 33 Resinous compounds 3 to 18 drocarbons, 13 to 20% of oil having aviscosity of about 280 seconds, Saybolt Universal at 110 F. and a pourpoint at about 25 F., 1 to 17% resin, and 40 to 50% asphalt hydrocarbonshaving a melting point above 90 F., and being adhesively bondable to the'masonry sections, said composition being characterized by a high degreeof distensibility and adhesiveness whereby the composition is deformablewithout shearing in response to the relative movement of said sectionsand capable of maintaining said adhesive bond with the sections atsub-freezing temperatures.

8. A water-stop expansion joint for bridging the space between andadhesively bonded with the adjacent ends of masonry sections comprisinga rubberized asphalt composition containing about 12 to 20% rubberhydrocarbons, 40 to asphalt, 13 to 20% of hydrocarbons having a meltingpoint above 90 F., and hydrocarbon oil having a viscosity of about 280seconds, Saybolt Universal at 110 F. and a pour point at about 25 F., 1to 17% resin, and 40 0t 50% asphalt, said composition beingcharacterized by a high degree of distensibility and adhesivenesswhereby the composition is deformable without shearing in response tothe relative movement of said sections and capable of maintaining saidadhesive bond with the sections at sub-freezing temperatures.

9. A water-stop expansion joint for sealing the space between theadjacent ends of masonry sections comprising a body having on oppositesides a rubberized asphalt composition containing about 12 to 20% rubberhydrocarbons, 13 to 20% of oil having a viscosity of about 280 seconds,Saybolt Universal at 110 F. and a pour point at about 25 F., 1 to 17%resin, and 40 to 50% asphalt hydrocarbons having a melting point above90 F., and being adhesively bondable to the masonry sections, saidcomposition being 10 characterized by a high degree of distensibilityand adhesiveness whereby the composition is deformable without shearingin response to the relative movement of said sections and capable ofmaintaining said adhesive bond with the sections at sub-freezingtemperatures.

10. A water-stop expansion joint for sealing the space between theadjacent ends of masonry sections comprising a body having on oppositesides a rubberized asphalt composition containing about 12 to 20% rubberhydrocarbons, 40 to 50% asphalt hydrocarbons having a melting pointabove F., and 13 to 20% of hydrocarbon oil having a viscosity of about280 seconds, Saybolt Universal at F. and a pour point at about 25 F., 1to 17% resin, and 40 to 50% asphalt, said composition beingcharacterized by a high degree of distensibility and adhesivenesswhereby the composition is deformable without shearing in response tothe relative movement of said sections and capable of maintaining saidadhesive bond with the sections at sub-freezing temperatures.

11. A water-stop expansion joint composition for sealing the spacebetween the adjacent ends of masonry sections comprising a rubberizedasphalt composition containing 12 to 20% rubber hydrocarbons, 13 to 20%of oil having a viscosity of about 280 seconds, Saybolt Universal at 110F. and a pour point at about 25 F., 1 to 17% resin, and 40 to 50%asphalt hydrocarbons having a melting point above 90 F., and beingadhesively bondable to the walls of the space between the masonrysections, said composition being characterized by being sluggishlydeformable in response to relative movement of the masonry tween thesections.

ALBERT C. FISCHER.

' REFERENCES CITED The following references are 01' record in the fileof this patent:

UNITED STATES PATENTS Number Name Date 2,221,431 Omansky NOV. 12, 19402,334,183 Fischer Nov. 16, 1943 2,339,556 Greenup Jan. 18, 19442,374,186 Fischer Apr. 24, 1945

